Fibrous web and methods and apparatus for producing the same



H. H. scHlEss 3,066,358

R PRODUCING THE: SAME Dec. 4, 1962 FIBROUS WEB AND METHODS AND APPARATUSFO Filed Nov. 18, 1957 2 Sheets-Sheet l H. H. SCHIESS PRODUCING THE SAMEDec. 4, 1962 FIBROUS WEB AND METHODS AND APPARATUS FOR 2 Sheets-Sheet 2Filed Nov. 18, 1957 ATTORNEY United States Patent Office 3,066,358Patented Dec. 4, 1962 3,066,358 FIBROUS WEB AND METHGDS AND APPARATUSFOR PRODUCING THE SAME Hans H. Schiess, Metuchen, NJ., assignor toChicopee Manufacturing Corporation, a corporation of New Jersey FiledNov. 18, 1957, Ser. No. 697,138 Claims. (Cl. 19--155) The presentinvention relates to a nonwoven web of fibrous materials and to improvedmethods and apparatus for producing the same. More specifically, thepresent invention is concerned with a nonwoven web of fibrous materialswherein the fibers are oriented predominantly in one direction and lieat an angle -to the long axis of the fibrous web.

Nonwoven webs of fibrous materials and nonwoven` fabrics made therefromhave become increasingly important in the textile industry during Ithepast decade because of their low cost of manufacture for a givencoverage, as compared to more conventional textile fabrics formed byweaving, knitting and felting operations.

Nonwoven fabrics are conventionally manufactured at the present timefrom a basic starting material comprising a more or less tenuous web ofloosely associated textile bers disposed in sheet form. The conventionalbasic starting material for nonwoven fabrics is a web comprising any ofthe common textile-length fibers, or mixtures thereof, the fibersvarying in length from about one-half inch in length to about two andone-half inches. Illustrative of such fibers are the natural fibers,notably cotton, the synthetic fibers, notably rayon, cellulose acetateand nylon; or mixtures thereof. These fibers are conventionallyprocessed through suitable textile machinery, such as a conventionalcard to form a fibrous web or sheet of loosely associated fibersweighing from about 100 grains to about 2000 grains or more per squareyard.

This essentially two-dimensional web or sheet of fibers is producedcontinuously with the fibers predominantly oriented in the machinedirection, i.e., the major or long axis of the fibrous web, which is thedirection in which the web moves continuously from the carding machine.In such a web, the degree of fiber orientation in the machine directionmay range from about 70% to about 90% or higher.

The two terms employed in the preceding paragraph to describe the fiberorientation in a card web should be explained. It is difficult todetermine fiber orientation directly and precisely in a card web`because the individual fibers of the web are in fact curled and bent,with different segments of each fiber extending in various directions.However, two kinds of average orientation may be ascertained which arehelpful in describing such a web. One of these is called the degree offiber orientation in a given direction. The other may -be called thedirection of predominant fiber orientation.

The degree of fiber orientation in the machine direction is determinedby (l) bonding the card web uniformly with a material such as starch,(2) drying the bonded web, (3) measuring tensile strengths lengthwiseand crosswise of the resulting fabric, and (4) computing the percentageof lengthwise or long strength of the fabric For simplicity, a web offibers having a degree of fiber orientation if desired be thought of inidealized form as having of its fibers substantially parallel to thelong axis of the web and 10% substantially parallel to the cross axis ofthe web.

Another idealized conception of a card web having fibers 90% oriented inthe machine direction-which conception is still more helpful inconnection with any discussion of the present invention and which leadsto a definition of direction of predominant fiber orientationis to thinkof the card web as comprised entirely of pairs of straight, crossedfibers with each fiber of any given pair lying upon the hypotenuse of aright triangle whose side parallel to the machine direction is 90 unitslong and whose side lying perpendicular to the machine direction is lOunits long. Each separate fiber of such a crossed pair of fibers isinclined more toward-the long axis of the web than toward the crossaxis, and thus the fibers as a group are said to be predominantlyoriented in the machine direction. The term direction of predominantorientation of the fibers of a web is thus employed in thisspecification and claims to mean that direction which bisects the acuteangle between any pair of cross fibers in this idealized conception ofan oriented web.

The idealized conception of a card web under discussion reflects certainphysical measurements that can be made with such a web. Because of thenature of a card web, there will always be two directions: of maximumtensile strength in a fabric formed by bonding the web. Except for thespecial case in which these two directions lie at right angles to eachother, there will be an acute angle which can be plotted between them.The bisector of this acute angle is the direction of predominantorientation of the card web fibers.

It follows that the direction of predominant fiber orientation can bemeasured by making certain physical determinations in much the samemanner as the degree of fiber orientation can be measured. The directionof predominant fiber orientation can be determined by (l) bonding thecard web uniformly, (2) drying the bonded web, (3) measuring tensilestrengths in all directions around the compass, (4) plotting theresulting data in a polar diagram, (5) determining the two directions inwhich maximum tensile strength is exhibited by the bonded fabric, and(6) determining the direction which bisects the acute angle between thetwo directions of maximum tensile strength.

Because of the drafting action of a cardingmachine, the fibers in a cardweb are always predominantly oriented in the machine direction. Thedegree of fiber orientation in the machine direction, however, dependsupon the severity of the drafting action and the extent to which it iscontinued during carding. t l

The webs produced by a carding machine are further processed and bondedby various methods known to the art and which do not relate directly tothe present inventive concept. Regardless of the further processing,however, the basic fact remains that the fibers are predominantlyoriented in the longitudinal direction of the web, which leads to manyadvantages and some disadvantages in the bonded fabric.

The most important of these disadvantages is the differ.- ence in thephysical properties and characteristics, notably the strength, of thebonded nonwoven fabric in the long direction, as compared to the crossdirection. This, of course, is due to the fact that the fibers liepredominantly oriented to the long axis and thus give the bonded fabricconsiderable strength in the long direction whereas they produce little,if any, strength in the cross-direction.

Much effort has been expended, for example, in lamiin the machinedirection of 90% might nating and bonding several of these webs togetherwith their oriented iibers and long axes at angles to each other toequalize the strengths in the long and cross directions. Such effortshave produced nonwoven fabrics which do not contain the greatdifferences in properties and characteristics measured in differentdirections which their predesc'essors possessed, but the expensivenature of their production has 'rendered them of dubious commercialvalue.

A principal object of the present inventive concept is to provide anonwoven web of fibrous materials wherein the Ifibers lie predominantlyoriented to the long axis of the web and at an angle thereto, which webwill thereby be a better basic'starting material for the manufacture ofnonwoven fabrics.

The predominantly oriented fibers may lie at any desired angle to thelong axis of the web, a 45 angle being preferred. .Nonwoven fabricshaving substantially even strength and other substantially uniformproperties and characteritics in all directions are obtained bylaminating two preferred Webs in accordance with the invention, with theoriented fibers in one web 'at right angles to those in the other, andthen bonding the laminate with any desired adhesive.

Avfurther principal object of the present invention is to providemethods and apparatusfor making such a nonwoven web.

In the accompanying drawings and the following specication, there isillustrated and described a preferred embodirnent of the improvednonwoven web of fibrous materials in accordance with the invention, aswell as preferred embodiments of methods and apparatus for producing thesame, but it is to be 'understood that the inventive concept is not tobe considered as limited to the embodiments disclosed, except asdetermined by the scope of the appended claims. Referring to theaccompanying drawings,

FIGURE 1 is a schematic perspective'view of apparatus for making anonwoven web of fibrous material embodying the present inventiveconcept;

g 4FIGURE 2 is a schematic plan view of apparatus such as shown'inFIGUREl but showing its use in making a twolayer,'crosslaid fibrous web;

FIGURE 3 isa schematic fragmentary View of the main card cylinder anddoffer belt of theV present invention showin'gthe construction of vthewires thereon;

FIGURE 4 is a vector diagram showing the velocity v ectors'ofthe maincylinder and the dofngbelt and the resultant vector velocity'or theangle of fiber deposition on the dofing belt;

`FIGURE 5 is a schematic perspective view of a modification of the"apparatus for making a nonwoven web of fibrous materials embodying thepresent inventive lconcept; V

FIGURE 6 is a schematic plan view of apparatus such 'as shown in FIGURE5 but showing its use in making a two-layer, cross-laid fibrous web; and

FIGURE 7 is Va schematic fragmentary view ofthe apparatus of FIGURES 5and 6 showing the construction of the wires on the vmain cardcylinder,the dofing cylinder and the doffiug belt.

Asshown in FIGURES `1 and 2, a main card cylinderV -10 is positioned soas to rotate with the plane of its direction of rotation and predominantfiber orientation at an angle at to the direction of travel of a doflingbelt 12. This'angular relationship of the card cylinder and the doifingbelt may be varied Within rather wide limits to meet any desired need,as hereinafter described. For ernphasis, the fibers are shown as havinga degree of fiber Vorientation of 95% or so on the main card cylinder.

The main card cylinder 10 is of the conventional type used in thetextile industry and comprises a large cylindrical cast-ironshellsupported by spiders (not shown) of the usual type. Theshell has aWidth of about 45 inches andan outside diameter of about 5() inches. The

surface of-the cylinder isv covered or helically wrapped in theconventional manner with the usual card clothing (see FIGURE 3)containing many fine, closely spaced, specially bent wires 11 having adiameter of from about 0.009 to about 0.017 inch. The cylinder 10 ismounted on a main drive shaft 14 and during carding operations is drivenin the direction indicated at a rotational velocity under normalconditions of from about to about 300 revolutions per minute andpreferably from about to about 220 revolutions per minute during cardingoperations. 'Ihis is equivalent to a peripheral linear surface velocityof from about 650 yards per minute to about 1300 yards per minute andpreferably from about 690 to about 960 yards per minute.

Other conventional parts of the card such as the feed works whichinclude the feed plate and feed roll, the licker-in, the mote knives,the licker-in screen, etc., have been omitted from the drawings for thepurpose of clarity. Since the main card is rotating in a clockwisedirection with the doffing belt travelling to the left in FIGURES l and2, the feed Works would be positioned in front of the main card cylinderrather than to the rear or behind the cylinder, as viewed in FIGURE l,and so would obscure the view of the main card cylinder if shown. Otherconventional card elements, such as the back-plate, the card flats,etc., have also been omitted to show more clearly the predominantorientation of the fibers on the main card cylinder.

The doffing belt 12 comprises an endless belt which is mounted on and ismoved continuously by either of the driving rolls 16 and 18 in thedirection indicated. The doffing belt 12 may have a width correspondingto the width of the card cylinder but this width may be less dependingupon the particular angular positioning of the doffing belt with respectto the card cylinder. The doffing belt may have a width greater than thewidth of the card cylinder but this is of no moment.

The doffing belt 12 is covered or wrapped with card clothing containingmany fine, closely spaced, specially bent wires 13 (see FIGURE 3) ofabout the same construction aild neness as the card clothing on the maincylinder. The iineness ofthe wires on the dotfing belt may be variedwith respect to the ineness of the wires on the card cylinder. Thus,they may be slightly finer or even slightly coarser. The doffing belt12is made of rubber, leather, synthetic materials, or other equivalent'flexible materials vin which the wires 13 are mounted similarly to themounting of the card wires 11 upon card cylinder 10.

In the embodiment shown in FIGURES l-3, the doffing belt`12 moves at aconsiderably slower linear velocity than the linear surface velocity ofmain cylinder 10 and, under normal conditions, has a linear velocity inthe range of from about 15 yards per minute to about 100 yards perminute and preferably from about 20 to about 70yards per minute. This isso because in the transfer or doffing of the iibersfrom the main cardcylinder to the doifing belt, the bends in wires 11 should preferably beopposed to the bends in'wires 13 and the hooks formed by the bends mustmove in opposition one to the other, when conventional card clothing isemployed.

The linear surface velocity of the main cylinder 10 and the linearvelocity of the doffer belt 12 may be variedV slightly from the rangesset forth above, depending upon the particular conditions involved but,in any event, the ratio of the linear surface velocity of the maincylinder 10 to the linear velocity of the doffer belt 12 should be atleast about l0 to 1 for satisfactory commercial operation, assuming thefibers in the resulting fibrous web arc torbe at about 45 to thelongitudinal axis of the web. Preferred ratios of these velocities rangefrom about 20 to 1 to about 60 to 1.

Velocity ratios of lessthan 10 to l maybe used, such as downto 5to 1 oreven lower, but, as will be discussed hereinafter, such lower ratiosintroduce greater discrepancies between the direction of rotation of`the'main'card cylinder and the actual direction at which the fibers aretransferred from the wires il of the main card cylinder 10 to the Wires13 of the doiier belt 12.

The main cylinder l is so positioned and spaced relatively with respectto the moving upper surface of' the doifing belt l2 as to establishsubstantially a continuous line of close proximity therewith wherebyfibrous materials may be dotted from the main cylinder 10 andtransferred to the moving belt l2 in the same way as fibers aretransferred from the main card cylinder to the dotfer roll in theconventional carding machine. rhe exact angularity and nature of thecontinuous line of close proximity between the main cylinder and thedoiing belt is obtained by making either or both adjustable with respectto each other to control their clearance and rspacing and theirangularity.

An adjusting or positioning rod or roller i9 may be positioned directlybelow the upper reach of the doier belt 12 to adjust its verticalpositioning and clearance with respect to the main card cylinder l0. Therod or roller i9 may be adjustable, as desired, and is then capable ofbeing secured in position whereby the clearance between the wires l1 ofthe main card cylinder 10 and the wires 13 of the dofling belt i2 ismaintained. This clearance is the usual clearance conventionallymaintained between a card cylinder and a doling roll and is on the orderof from about 0.005 inch to about 0.020 inch and is normally about 0.007inch for cotton, for example.

Adjustability of the angular relationship between the main card cylinderand the doing belt is normally obtained by manually positioning the twoat the desired angle and securing them in the desired position. In theevent that frequent changes of the angular relationship are required, itis preferable to mount the doifing belt in an adjustably rotatablecradle so constructed as to rotate substantially in a plane.

The exact mechanism of the iiber transfer from the main cylinder to thedofling belt is not precisely known but it is believed that the iiberson the wires of the card clothing of the main cylinder make pointcontact with the wires of the card clothing on the doiling belt and aretransferred thereto. The relatively higher velocity of the maincylinder, however, causes the individual fibers to be laid inpredominantly oriented relationship on the surface of the doiiing belt,tending to keep their original dominant orientation which prevailed onthe main cylinder rather than taking the direction of movement of thedoier belt. At the same time, the fibers shift to and movesimultaneously with the dofer belt in the new changed direction. As aconsequence, the fibers remain substantially in their originalpredominant orientation but sidle or move sidewise forwardly at an angleto the long direction of the web now on its new carrier, namely, thedoffer belt.

More precisely, the actual angles of individual fiber deposition and theresulting predominant orientation of the whole group of fibers on thedofiing belt are not eXactly the same as the individual ber angles andpredominant orientation that obtained on the main card cylinder.Strictly speaking. the angle of fiber deposition on the doiiing belt ofa fiber lying on the card cylinder in a position parallel to thedirection of rotation of the cylinder is the angle of the resultantvector of l) the large velocity vector of the linear surface velocity ofthe main cylinder which is the direction of rotation thereof and (2) therelatively small velocity vector of the doifer belt which is itsdirection of movement. A vector diagram is shown in FIGURE 4 for thevelocities and their directions when the main cylinder and the doftingbelt are positioned at an angle a of 45 and the linear surfacevelocities of the main cylinder and the doiiing belt have a ratio ofabout l5 to l. It is to be observed that the resulting angle of fiberdeposition is about 3 less than the angle of the linear surface velocityvector for the main cylinder under the conditions stated. This angle is,of course, relatively very small and becomes negligible as the ratio ofthe velocities increases. On the other hand, if velocity ratios of lessthan l5 to l, say as low as 5 to 1 or lower, are used, this angle willincrease considerably above 3 If it is desired to make an adjustment forthis increased ang e by increasing the angular relationship between themain card cylinder and the dotiing belt, this will increase the densityand decrease the width of the resulting fibrous web.

The fibers thus hooked by the wires of the doiiing belt from the wiresof the main cylinder and laid thereon are carried forwardly by thedoiing belt in the changed direction in predominant orientation but, asdescribed previously, since they were deposited on the doffer belt withsubstantially the same predominant orientation and direction which theypossessed on the main cylinder, their direction of predominantorientation is now disposed at an angle to the long axis of the doierbelt. This is shown most clearly in FIGURE 2.

The fibers may then be removed from the doliing belt by a second doiiingmeans such as the usual doffer comb but preferably by a perforated drum20 provided with a suction manifold 22. A device such as illustrated inU.S. Patent 2,077,095, issued April 13, 1937,` to E. L. Cady may beemployed.

The nonwoven fibrous web W is then deposited on a main conveyor belt 24upon which has been previously deposited another nonwoven web such asweb W (see FIGURE 2) wherein the fibers are predominantly oriented at anangle of 45 in the opposite angular direction to the long axis of thedirection of movement of the web, or in other words with the directionof predominant orientation of the fibers in one web substantially atright angles to the direction of predominant orientation of the bers inthe other web. The resulting composite twolayer, cross-laid nonwoven webpossesses more even strength and other physical properties andcharacteristics in all directions.

In the event that it is desired to have a greater equalization of thestrength and other physical properties and characteristics in alldirections, up to as many as 8 webs or more may be cross-laid in thisway or at angles of 45 to each other to form a composite fabric. If likeproperties are desired in all directions for the resulting laminatedweb, the directions of predominant orientation of the fibers in therespective layers should be distributed at equal angular incrementsaround the compass. In the event that unequal strengths are desired inpreselected directions and proportions, such can be arranged by merelycross-laying the various webs with their respective directions ofpredominant iiber orientation at unequal angular spacing to accomplishthe desired result. Within the more commercial aspects of the presentinvention, nonwoven fabrics comprising 4 webs with each web having adirection of predominant fiber orientation at 45 to the predominantliber orientation of the next web have been found most practical.

Although the present inventive `scribed and illustrated with the.tangential direction of rotation of the main cylinder and ythedirection of movement of the doing belt vat the line of close proximitytherebetween disposed at an angle of 45 to each other, it is to beyappreciated that other angles may be selected depending upon ytheparticular circumstances involved. Por example, ian langle as high asabout 60 may be employed, although it must be observed that the greaterthe angle, the greater is the loss in Width and Ithe increase in densityof the nonwoven web which is being 'transferred from the main cylinder.This is, of course, obvious from the geometry of the angularrelationship involved inasmuch as the greater the angle, the greater isthe degree of condensation of the resulting web. The 'angularrelationship may lbe decreased below 45 for example, to 30 or even to 15whereby 'the decrease in width is less but wherein the angularity of theiibers in the web with respect to vthe longitudinal axis of the concepthas been deproximity between the cylinder and the doiiing 1reciprocal ofweb is also less. Decreasing the `angle below 15 to about 5 decreasesthe angularity of the deposited fibers with respect to the long axis ofthe fibrous web whereby the effect of .the present inventive conceptbecomes less and less noticeable. These angles, `of course, relate tothe angle between the tangential direction of movement of the fibers onthe main cylinder at the line of close belt, and the `direction ofmovement of the lfibers on the dofng belt.

-It is .to be observed that, although the width of the web is narrowedduring the transfer from the main cylinder to Ithe doiiing belt, thereis an approximately corresponding increase in the weight per square yardof the web. That is to say, whenever the width of the web is reduced toa given fraction of its original value, the weight per square yard ofthe fabric increases by the that fraction.

Although the inventive concept has been described with particularreference to the transfer of fibers from the main cylinder to thedoliing belt, it is to be appreciated that it is not to be construed aslimited therelFor example, as shown in `FIGURES 5 -and 6 the fibers canbe transferred directly and without any change in their angulardirection dofling cylinder or roll 15 of the usual type and thentransferred ,from the dofiing roll 15 to the doffing belt 12 with theirdirection of predominant ber orientation changed in accordance with themethod of this invention. This may require an adjustment of the velocityof the main cylinder and of the doffing roll 15, so that the requiredlinear surface velocity differential is maintained as explained abovebetween the doiiing belt and the doiiing roll. it is preferred that theconventional differential be maintained between :the linear surfaceveloci-ty of the main cylinder and the linear surface velocity of thedoffing roll, although this is not required. For best results wi-thconventional card clothing, the bends in wires 11 on the main cy-lindershould be opposed to the bends in wires 17 on the doiiing roll, and thehooks formed by the bends should move in opposition one to the other, asshown in FIGURE, 7.

Similarly, .the bends in wires 13 of the dofling belt 12 should beopposed to the bends in wires 17 on the dofiing roll, and the hooksformed by the bends should move in opposition to each other, wheneverconventional card clothing is used. It is also important that there be arelative differential between the linear surface velocity of the doiiingroll 1S and the linear surface velocity of the dofiing belt 12 that,falls more or less within the ranges explained above. Within the morecommercial aspects of the present invention, a linear speed differentialof at least 10 to 1 should be desirably maintained between the doiiingroll and the doffing belt.

The relationship of the main card cylinder 10, the doifer 15 and thedotiing belt 12 may be as illustrated in FIGURE 7. The directions ofrotation of the main cylinder and of the doffer and the direction ofmovement of lthe doffer belt are as indicated by the arrows, in -thisembodiment. The bers are transferred from wires 11 on .the main cardcylinder 1b to wires 17 on the doifer 15. The web of fibers so receivedon the wires 17 of the doffer 15 is then transferred to the wires 13 ofthe moving doffer belt 12. The basic doliing principles are, of course,similar to those involved when merely a main card cylinder and a doffingbelt are employed.

The invention will be further illustrated in greater detail by thefollowing specific examples. It should be understood, however, thatValthough these examples may describe in particular detail some of themore specific features of the invention, they are given primarily forpurposes 'of illustration and the invention in its broader aspects isnot to be construed as limited thereto.

from a main cylinder 1G to a` Vdoliing belt linear velo-c (..J Example 1A nonwoven web of fibrous materials is prepared with apparatusillustrated in FGURES 1 and 2 as follows: The main card cylinder iswrapped with Z-inc'n fillet card clothing. it has a width of 45 inches,ian outside diameter of 50 inches and is operated lat about 170revolutions per minute for a linear surf-ace verocity of about 740 yardsper minute. The doffer belt is also wrapped with 2-inch fillet cardclothing. rffne belt has a width of 32 inches and a length betweendriving rollers of about 88 inches. lt is oper-ated at a linear surfacevelocity of about 25 yards per minute. The ratio of the main cardcylinder linear surface velocity to the belt linear velocity is about 29to 1. The fibers used are viscose rayon having an average staple lengthof about 2 inches. The langle a between the plane of the direction ofrotation and predominant fiber orientation of the main cylinder and thedirection of travel of the doifer belt is 45. The clearance between themain cylinder and the dofling belt is 0.007 inch. The fibers are fed tothe main card cylinder and are carded into predomiorientation on themain card cylinder in the direction of rotation thereof in accordancewith known procedures. The carded fibers are doffed from the maincylinder to the doffer belt and then are transferred by suction means tothe main conveyor belt where they are plied with another web containingfibers oriented 45 in the opposite direction. The width of the resultingcross-laid nonwoven fabric is about 3i inches. The weight of the fabricis about 40() grains per square yard and it possesses approximatelyequal strengths (1:1) in the long and cross direction. The nonwovenfabric is bonded with a dispersion of polyvinyl acetate to deposit about5% solids by weight (dry basis) thereon. r[he resulting nonwoven fabricis useful as a dinner place-mat.

Example 2 A nonwoven web of fibrous materials is prepared by theprocedures of Example 1, except that the main card cylinder surfacevelocity is increased to about 190 revolutions per minute or 830 yardsper minute. The ratio of the main card cylinder linear surface velocityto the ity is therefore about 33 to l.

Although the fibrous materials on the main card cylinder have beenreferred to in this disclosure in such terms as to create the impressionthat a web of fibers exists thereon, such is true only in the very broadsense. Precisely speaking, these fibrous materials are in the form ofindividual fibers but, when considered in gross, may be collectivelyconsidered looseiy as a web of fibers existing in a sort of sheet-likeform having long and cross directions.

Although specific examples of the inventive concept have been described,the same should not be construed as limited thereby nor to the specificembodiments shown but to include various other equivalent embodiments asset forth in the claims appended hereto. It is understood that anysuitable changes7 modifications and variations may be made withoutdeparting from the spirit and scope of the invention.

This patent application is a continuation-in-part of my earlier filedpending patent application entitled: Fibrous Web and Method andApparatus for Producing the Same, Serial Number 694,642, tiled on orabout November 5, 1957, now abandoned.

I claim:

1. Apparatus for forming a web of fibrous materials wherein the fiberslie in a direction of predominant orientation at an angle to the longaxis of the web which cornprises a continuously rotatable card cylinderfor orienting the fibers on the surface thereof with their direction ofpredominant fiber orientation lying in a plane at right angles to theaxis of the cylinder, and for conveying said fibers at a relatively highvelocity in the direction of their predominant orientation, and adofiing belt bearing card clothing, said dofiing belt being continuouslymovable at a relatively low velocity in a direction at an angle to saidplane and being positioned so as to have a line of close proximity withsaid card cylinder and diverge from the surface thereof on either sideof said line of-close proximity, said angle between said plane and thedirection of movement of said doing belt being from about to about 60,whereby said oriented fibers may be transferred from said card cylinderto said doiiing belt with their velocities reduced to a small fractionof their original relatively high velocity, but with substantially thesame predominant orientation with respect to the surrounding environmentas they had immediately before such transfer, thereby to form a looselyassociated nonwoven web in which the fibers lie on said `dofiing belt atan angle to the long axis of the web.

2. Apparatus as defined in claim l wherein said plane containing thedirection of predominant fiber orientation and the direction of movementof the dofiing `belt are atan angle of from about 15 to about 60 to eachother.

3. Apparatus as defined in claim l wherein said plane containing fthe`direction of predominant fiber orientation and the direction ofmovement of the doffing belt are at an angle of from about 30 to about45 to each other.

4. Apparatus as defined in claim 1 wherein supporting means is providedto maintain the card cylinder and dofiing belt in accurately spacedsubstantial line proximity relationship.

5. Apparatus for producing a continuous assemblage o-f fibers in whichthe direction of predominant fiber orientation is at an angle to thelongitudinal axis of the fiber assemblage which comprises: means forsupporting a plurality of fibers in dispersed positions and insubstantial parallelism to each other, said fiber supporting meanshaving a circular cross section taken in any plane parallel to a givenplane and being rotatable at a relatively high angular velocity in adirection parallel to said given plane; means for rotating said fibersupporting means; movable fiber receiving means having a continous lineof close proximity with said fiber supporting means, said fiberreceiving means being movable at a lower linear speed than the linearsurface speed of said fiber supporting means and in a direction at anangle to said given plane, said angle being from about 5 to about 60,said line of close proximity being maintained during simultaneousrotation and movement of said fiber supporting and fiber receivingmeans, respectively, the surfaces of said fiber supporting and receivingmeans diverging as they extend on either side of said line of closeproximity; and means for moving said fiber receiving means.

6. A method of continuously forming a web of fibrous materials whereinthe fibers lie in a direction of predominant orientation at an angle tothe long axis of the web which comprises: orienting the fiberspredominantly in a given direction in an arrangement defining anorienting surface; conveying them at a relatively high velocity in thedirection of their predominant orientation; changing the direction ofsaid fiber movement in an amount from about 15 to about 60; andsimultaneously reducing the velocity thereof to a small fraction of theoriginal velocity, whereby said fibers become loosely associated in anonwoven web, said fibers, when disposed upon the receiving surface,retaining substantially the same predominant orientation but moving inthe changed direction at an angle of from about 15 to about 60 to thelong axis of the moving web.

7. A method of continuously forming a web of fibrous materials whereinthe fibers lie in a direction of predominant orientation at an angle tothe long `axis of the web which comprises: orienting the fiberspredominantly in a given direction in an arrangement defining anorienting surface; conveying them at a relatively high velocity in thedirection of their predominant orientation; changing the direction ofsaid lfiber movement in an amount from about 30 to about 45; andsimultaneously reducing the velocity thereof to a small fraction of theoriginal velocity, whereby said fibers become loosely associated in anonwoven web, said fibers, when disposed upon the receiving surface,retaining substantially the same predominant orientation but moving inthe changed direction at an angle of from tabout 30 to about 45 to thelong axis of the moving web.

8. A method of producing a continuous brous web in which the directionof predominant fiber orientation is at a desired angle -of more than 5and up to 60 to the longitudinal axis thereof which comprises: moving afibrous web comprising a plurality of fibers oriented predominantly in agiven direction in one direction on a first movable surface, thedirection of predominant fiber orientation, the direction of movement ofsaid fibrous web, and the direction of movement of said rst movablesurface being substantially the same; and transferring said `fibrous webfrom said first movable surface to a second movable surface having acontinuous line' of close proximity with said first movable surface,said second movable surface moving at a lesser linear speed than thefirst movable surface and in a direction having a predetermined angle ofmore than 5 and up to but not greater than about 60 to a plane normal tosaid continuous line of close proximity whereby the direction ofpredominant fiber orientation of said fibrous web on said second movablesurface possesses said predetermined angle of more than 5 and up to butno greater than about 60 to the direction of movement of said fibrousweb and to the direction of movement of said second movable surface.

9. A method of producing a continuous fibrous web in which the directionof predominant fiber orientation is at a desired angle of more than 5and up to 60 to the longitudinal axis thereof which comprises: moving afibrous web comprising a plurality of fibers oriented predominantly in agiven direction in one direction on a first movable surface, thedirection of predominant fiber orientation, the direction of movement ofsaid fibrous web, and the direction of movement of said first movablesurface being substantially the same; transferring said fibrous web fromsaid first movable surface to a second movable surface having acontinuous line of close proximity with said first movable surface, saidsecond movable surface moving at a lesser linear speed than the firstmovable surface and in a direction having a predetermined angle of morethan 5 and up to but no greater than about 60 to a plane normal to saidcontinuous line of close proximity whereby the direction of predominantfiber orientation of said fibrous web on said second movable surfacepossesses said predetermined angle or more than 5 and up to but nogreater than about 60 to the direction of movement of said fibrous weband to the direction of movement of said second movable surface; andconveying said fibrous web away from said continuous line of closeproximity.

`l0. A method of producing a continuous fibrous web in which thedirection of predominant fiber orientation is at a desired angle' ofmore than 5 and up to 60 to the longitudinal Iaxis thereof whichcomprises: moving a fibrous web comprising a plurality of fibersoriented predominantly in a given direction in one direction on arotatable surface, the direction of predominant fiber orientation, thedirection of movement of said fibrous web, and the direction of movementof said rotatable surface being substantially the same; and transferringsaid fibrous web from said rotatable surface tro a movable surfacehaving a continuous line of close proximity with said rotatable surface,said movable surface moving at a lesser linear speed than the rotatablesurface and in a direction having a predetermined angle of more than 5and up to but no greater than about 60 to a plane normal to saidcontinuous line of close proximity whereby the direction of predominantfiber orientation of said fibrous web on said movable surface possessessaid predetermined angle of more than 5 and up to but no greater thanabout 60 Y accesso to the direction of movement of said fibrous web andtothe direction of movement of said movable surface.

11. A method of producing a continuous fibrous Web in which thedirection of predominant fiber orientation is at a desired angle of morethan 5 and up to 45 to the longitudinal axis thereof which comprises:moving a fibrous web comprising a plurality of fibers orientedpredominantly in aV given direction in one direction on a first movablesurface, the direction of predominant fiber orientation, the directionof movement of said fibrous web, and the direction of movement of saidfirst movable surface being substantially the same; and transferringsaid fibrous web from said first movable surface to a second m-ovablesurface having a continuous line of close proximity with said firstmovable surface, said second movable surface moving at a lesser linearspeed than the Vfirst movable surface and in a direction having apredetermined angle of more than 5 and up to about 45 to a plane normalto said continuous line of close proximity whereby the direction ofpredominant fiber orientation of said fibrous web on said second movablesurface possesses said predetermined angle of more than 5 and up to butno greater than about 45 to the direction of movement of said fibrousweb and to the direction of movement of said second movable surface.

l2. A method of producing a continuous fibrous web in which thedirection of predominant fiber orientation is at a desired angle of morethan 5 and up -to 45 toy the longitudinal axis thereof which comprises:moving a fibrous web comprising `a plurality of fibers orientedpredominantly in a given direction in one direction on a rotatablesurface, the direction of predominant fiber orientation, the directionof movement of said fibrous web, and the direction of movement of saidrotatable surface being substantially the same; and web from saidrotatable surface to a movable surface having a continuous line of closeproximity Vwith said rotatable surface, said movable surface moving at alesser linear speed than said rotatable surface and in a directionhaving a predetermined angle of more than 5 and up to about 45 to aplane normal to said continuous line of close proximity whereby thedirection of predominant fiber orientation of said fibrous web on saidmovable surface possesses said predetermined angle or more than 5 and upto but no greater than about 45 to the direction of movement of saidfibrous web and to the direction of movement of said movable surface.

13. Apparatus for producing a continuous fibrous web in which thedirection of predominant fiber orientation is at a desired angle of morethan 5 and up to 60 to Vthe longitudinal axis thereof which comprises: afirst movable surface for moving a fibrous web comprising a plurality offibers oriented predominantly in a given direction in one direction onsaid first movable surface, the direction of predominant fiberorientation, the direction of movement of said of movement of said firstmovable surface being substantially the same; and a second movablesurface for receiving said fibrous web from said first movable surface,said second movable surface having a continuous line of close proximitywith said first movable surface, said second movable surface moving at alesser linear speed than the first movable surface and in a directionhaving a predetermined angle of more than 5 and up to but not greaterthan about 60 continuous line of close proximity whereby the directionof predominant fiber orientation of vsaid fibrous web on said secondmovable surface possesses said predetermined transferring said fibrousto a plane normal to said` at a desired angle of more than 5 angle ofmore than 5 and upto but nogreater than about 60 to the directionofmovement of said fibrous web ,and to the direction of movement of saidsecond movable surface.

14. Apparatus for producing a continuous fibrous web in which thedirection of predominant fiber orientation is at a desired angle of morethan 5 and up to v60 to the longitudinal axis thereof which comprises: afirst movable surface for moving a fibrous web comprising a plurality offibers oriented predominantly in a given direction in one direction onsaid first movable surface, the direction of predominant fiberorientation, the direction of movement of said fibrous web, and thedirection of movement of said first movable surface being substantiallythe same; a second movable surface for receiving said fibrous web fromsaid first movable surface, said second movable surface having acontinuous line of close proximity with said first movable surface, saidsecond movable surface moving at a lesser linear speed than the firstmovable :surface and in a direction having a predetermined angle of morethan 5 and up to but no greater than about 60 to a plane normal to saidcontinuous line of close proximity whereby the direction of predominantfiber orientation of said fibrous web on said second movable surfacepossesses said predetermined angle of more than 5 and up to .but nogreater than about 60 to the direction of movement of said fibrous weband to the direction of movement of said second movable surface; andmeans for conveying said `fibrous ,web away from said second movablesurface.

r15. Apparatus for producing a continuous fibrous web in which thedirection of predominant fiber orientation is and up tov `6 0" to thelongitudinal axis thereof which comprises: a rotatable card cylinderhaving a rotatable surface for moving a fibrous web comprising aplurality of fibers oriented predominantly in a given direction in onedirection on said rotatable surface, the direction of predominant fiberorientation, the direction of movement of said fibrous web, and thedirection of movement of said rotatable surface being substantially thesame; and an endless dofiing belt having a movable surface for receivingsaid fibrous web from said rotatable surface, said movable surfacehaving a `continuous Vline of close proximity with the full fibrous web,and the directionV width of said rotatable surface, said movable surfacemoving ata lesser linear speed than said rotatable surface and in adirection having a predetermined angle of more than 5 and up to but nogreater than about 60 to a ,plane normal to` saidcontinuous line ofclose proximity whereby the direction of predominant fiber orienta--tion of said fibrous web on said movable surface possesses saidpredetermined angle of more than 5 and up to but no greater than about`6,0" to the direction of movement of said fibrous web and to thedirection of movement of said movable surface.

References Cited in the file of this patent UNITED STATES PATENTS

